Reinforced architectural panel

ABSTRACT

An architectural panel includes a substantially rectangular prismatic main body cast from lightweight concrete that has first and second major faces which are substantially planar and parallel to one another. First and second reinforcing mesh sheets are disposed substantially parallel to one another, next to the first and second major faces, respectively, and embedded in the main body. Recesses are arrayed in the first major face. Each recess extends through a respective opening in the first mesh sheet.

TECHNICAL FIELD

The present invention relates generally to architectural cladding and lining, and particularly to reinforced concrete panels.

BACKGROUND OF THE INVENTION

Modern large buildings generally consist of a basic load bearing structure supporting the exterior cladding and internal linings of the walls. This wall cladding or lining material should be lightweight, durable, of pleasing appearance and compatible with overall environmental objectives for the interior of the building. The interior or exterior of some buildings are finished in polished natural stone, such as granite or marble or in a decorative concrete finish. This has a pleasing appearance, but these panels are generally large, and in order to have sufficient strength to avoid breakage must be heavy. Mounting such stone and concrete panels can therefore be difficult, and in some cases there has been a tendency for unevenly distributed weight to cause panel joints to fail over time.

Architectural panels have been made from light weight reinforced concrete to address these difficulties. However, while satisfactory strength-to-weight ratios have been attained by some prior panels, their performance has typically been compromised in other respects, such as simplicity and cost of manufacture and thermal performance. It will be understood that there remains a need for an optimised or improved design which suffers less from such compromises. It is an object of the present invention to address this need or, more generally, to provide an improved architectural panel.

DISCLOSURE OF THE INVENTION

According to one aspect of the present invention there is provided an architectural panel comprising:

-   -   a main body cast from lightweight concrete;     -   first and second major faces on the main body which are         substantially planar and parallel to one another;     -   first and second mesh sheets disposed substantially parallel to         one another next to the first and second major faces         respectively and embedded in the main body such that edges of         each mesh sheet are disposed adjacent a respective edge of the         main body, the first mesh sheet defining an array of openings,         and     -   an array of recesses in the first major face, each recess         extending through a respective one of the openings in the first         mesh sheet.

It has been found that a panel according to the invention has a high strength-to-weight ratio, and exceptional thermal performance when correctly installed with the second major face disposed outwardly. In hot climates, when provision is made for air flow over the first major face, the panel is effective in reducing solar gains by dissipating heat to the air. In cool climates, when provision is made to prevent air flow over the first major face, the panel is effective in reducing heat loss from the building envelope.

Preferably the main body has a substantially rectangular prismatic form and the mesh sheets are rectangular.

Preferably no undercut is provided in the recesses.

Preferably each recess tapers inwardly from a mouth at the first major face to a base.

Preferably each recess comprises a plurality of intersecting flat faces. Preferably each recess comprises five flat faces.

Preferably the openings in the first mesh are square and the mouth is square.

Preferably four tapered faces of each recess extend from the square mouth to a square face at the base.

Preferably the four tapered faces have rotational symmetry about a central axis of each recess that extends substantially orthogonal to the first face.

Preferably the lightweight concrete may one of: sintered expanded clay as aggregate, expanded polystyrene beads as aggregate, pumice as aggregate, expanded shale as aggregate, bottom ash as aggregate, ceramics as aggregate, aerated concrete and foamed concrete.

Preferably a plurality of fixtures cast into the main body to provide for mounting points, each fixture comprising a plate fixed to a projecting bracket and extending substantially perpendicular to the plate, an aperture in the bracket with an internal screw thread.

Preferably the fixture has generally the same dimension as the thickness of the panel.

Preferably the fixtures are fixed to the mesh sheets.

Preferably substantially the full length of the bracket is embedded in the concrete.

Preferably a backing layer extends over the first major face and keyed into the recesses, formed as by casting the backing layer after the body.

Advantageously, a facing layer may be bonded to the second major face so as to be exposed on installation for aesthetic purposes. The facing layer may comprise lightweight concrete with a decorative finish, such as a patterned finish, or exposed aggregate finish. The facing layer may alternatively comprise stone, such as polished marble or granite. Optionally, a decorative finish may instead be applied directly to the second major face.

This invention provides an architectural panel which is effective and efficient in operational use, which may be economically constructed and has an overall simple design which minimizes manufacturing costs and improves structural and thermal performance.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred forms of the present invention will now be described by way of example with reference to the accompanying drawings, wherein:

FIG. 1 is an isometric view of a panel according to an embodiment of the invention;

FIG. 2 is a fragmentary section indicated by AA on FIG. 1;

FIG. 3 is a fragmentary section indicated by BB on FIG. 1;

FIG. 4 is a fragmentary section corresponding to FIG. 2 but showing an additional facing layer bonded to the panel of FIG. 1;

FIG. 5 is a longitudinal section through a fixture of the invention;

FIG. 6 is a fragmentary section through of a panel according to a second embodiment of the invention;

FIGS. 7 and 8 are fragmentary views of a major face of the panel of FIG. 6, and

FIG. 9 is a fragmentary section through of a panel according to a third embodiment of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1 to 3 of the drawings, a lightweight and structurally efficient architectural panel according to a first embodiment of the invention may have a generally rectangular prismatic main body 10 cast from lightweight concrete, and having a first major face 11 and an opposing second major face 12. The major faces 11, 12 are substantially planar and parallel to one another.

A rectangular array of recesses 13 are disposed in the first major face 11, and may be of like form and regularly spaced, with an uninterrupted margin 14 extending about the perimeter of the array of recesses 13 adjacent to a peripheral edge 15 of the main body 10.

The main body 10 is reinforced with first and second substantially rectangular reinforcing mesh sheets 17, 18 disposed substantially parallel to one another next to the first and second major faces 11, 12 respectively. A corner section of the mesh sheet 17 is illustrated by the dashed lines in FIG. 1, while both sheets 17, 18 are illustrated by the circular section wires in FIGS. 2-4. The mesh sheets 17, 18 may be made of stainless steel wire and are embedded in the main body 10 such that edges 19 of each mesh sheet 17, 18 are disposed inside and adjacent to the peripheral edge 15. Each mesh sheet 17, 18 defines an array of square openings 20, the two sheets being aligned such that the openings 20 are in registration with one another, and with the recesses 13.

Each recess 13 has a mouth 16 at the first major face 11 and tapers inwardly from the mouth 16 to a base 21. The base 21 is below the level of the mesh sheet 17 such that each recess 13 extends through a respective one of the openings 20 in the first mesh sheet 17, but stops short of the second mesh sheet 18.

Each recess 13 has a concave form without undercut, allowing the recesses to be cast readily. Each recess may have four intersecting planar faces 22 a-22 d that taper inward as they extend toward the base 16. A face of the base 21 forms a fifth face bounding the recess. In the preferred embodiment the mesh openings 20 and recesses 13 are centred on a transverse axis 24 that extends substantially orthogonal to the first and second major faces 11, 12, the recesses 13 having a symmetrical shape such that the four tapered faces have rotational symmetry about a central axis.

FIG. 4 illustrates a composite panel comprising a facing layer 26 bonded to the second major face 12 of the main body 10. The facing layer 26 may be formed with an exposed face 27 with a decorative finish, such as a patterned finish, or exposed aggregate finish.

The main body 10 and facing layer 26 may be cast from lightweight concrete, such as concrete including lightweight aggregates, especially expanded polystyrene beads, pumice, expanded shale, bottom ash and ceramics. Alternatively, the lightweight concrete may be foamed or aerated concrete. The panels are self-supporting but may be non-structural and suitable lightweight concretes may have a density of about 1400-1500 kg/m³ and compressive strength of 25-30 MPa.

Providing recesses 13 allows a further weight saving to be achieved and it is believed that the recessed inner major face 11 contributes to the improved thermal performance in reducing solar gains in hot climates (when provision is made for air flow over the first major face) by improving heat dissipation to the air. In cool climates, when made substantially airtight the recess provide a still air gap effective in reducing heat loss from the building envelope. The recesses 13 also provide suitable locations for fasteners for fixing the panels.

Referring to FIGS. 5-8, a plurality of fixtures 30 are cast into the main body 10, to provide mounting points on the panel for connection to the frame of a building. Each fixture 30 may comprise a plate 31 fixed to a projecting bracket 32, as by a screw fastener 33. The bracket 32 may extend perpendicular to the plate 31, and include a longitudinally through-extending aperture 34 with an internal screw thread 35. An opening in the plate 31 for receiving the screw 33 may be disposed generally centrally. The fixture 30 may have generally the same dimension as the thickness of the panel, such that the outer face 37 of the bracket 32 and outer face 36 of the plate 31 are generally coplanar with the first and second major faces 11, 12 respectively. Edges 39 of the recesses 13 may be radiused.

As best seen in FIGS. 6 and 7, the fixtures 30 may also be fixed to the mesh sheets 17, 18. By securing the mesh sheets 17, 18, as by welding, to the bracket 32 the fixtures 30 can also be used for supporting the mesh sheets 17, 18 in position during casting, as with the outer faces 36, 37 abutting opposite walls of a form (not shown) in which the panel is cast. The bracket 32 may be connected to both wires 40 a, 40 b of the mesh panels 17, 18 as by locating the bracket 32 adjacent the intersection between the wires 40 a, 40 b. Substantially the full length of the bracket 32 is preferably embedded in the concrete, and this is achieved by locating the fixtures 30 outside the recesses 13. For instance, as shown in FIG. 8, the regular, rectangular array of recesses 13 may be interrupted by areas adjacent the fixtures 30 without recesses 13.

FIG. 6 also illustrates a second embodiment of the architectural panel comprising the body 10 with a facing layer 42 bonded to the second major face 12 and formed, for instance, from stone. Strips 43 of the same stone as the facing layer 42 may be fixed along the edges of the panel. The outer face 36 may be bonded to the inner side 44 of the facing layer 42 as by a layer 45 of adhesive, such as epoxy. A cementitous bond is achieved between the rest of the inner side 44 and the body 10 by casting the body against the facing layer 42, and the edge strips 43.

A third embodiment of the architectural panel is illustrated in FIG. 9, having generally like construction to the second embodiment of FIG. 6, but further including a backing layer 50 extending over the first major face 11 and keyed into the recesses 13, being formed as by casting the backing layer 50 after casting the body 10 to provide a cementitous bond between the two. The backing layer 50 may be formed from a lightweight concrete of lower density than that of the body 10, and which provides increased thermal insulation. The backing layer 50 may be fibre reinforced, as by glass fibre or synthetic fibre, providing a high strength-to-weight ratio. The fixture 130 used with this panel is of like construction to the fixture 30, but includes a longer bracket 132 that extends to the rear face 51 of the backing layer 50.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof. 

1. An architectural panel comprising: a main body cast from lightweight concrete; first and second major faces on the main body which are substantially planar and parallel to one another; first and second mesh sheets disposed substantially parallel to one another, next to the first and second major faces, respectively, and embedded in the main body, wherein edges of each of the first and second mesh sheets are disposed adjacent respective edges of the main body, and the first mesh sheet includes an array of openings; and an array of recesses in the first major face, wherein each recess extends through a respective one of the openings in the first mesh sheet.
 2. The architectural panel of claim 1 wherein the main body has a substantially rectangular prismatic form and the mesh sheets are rectangular.
 3. The architectural panel of claim 1 wherein no undercut is provided in the recesses.
 4. The architectural panel of claim 1 wherein each recess tapers inwardly from a mouth at the first major face to a base.
 5. The architectural panel of claim 1 wherein each recess comprises a plurality of intersecting flat faces.
 6. The architectural panel of claim 1 wherein each recess comprises five flat faces.
 7. The architectural panel of claim 4 wherein the openings in the first mesh are square and each mouth is square.
 8. The architectural panel of claim 7 wherein each recess includes four tapered faces that extend from the square mouth to a square face at the base.
 9. The architectural panel of claim 8 wherein the four tapered faces have rotational symmetry about a central axis of each recess that extends substantially orthogonal to the first face.
 10. The architectural panel of claim 1 wherein the lightweight concrete comprises one of aerated concrete and foamed concrete, and, as aggregate, one chosen from the group consisting of: sintered expanded clay, expanded polystyrene beads, pumice, expanded shale, bottom ash, ceramics.
 11. The architectural panel of claim 1, further comprising a plurality of fixtures cast into the main body to provide mounting points, each fixture comprising a plate fixed to a projecting bracket extending substantially perpendicular to the plate, wherein each bracket includes an aperture with an internal screw thread.
 12. The architectural panel of claim 11 wherein the panel has a thickness and each fixture has a dimension generally the same as the thickness of the panel.
 13. The architectural panel of claim 11 wherein the fixtures are fixed to the first and second mesh sheets.
 14. The architectural panel of claim 11 wherein the bracket has a length and substantially all of the length of the bracket is embedded in the concrete.
 15. The architectural panel of claim 1, further comprising a backing layer extending over the first major face and keyed into the recesses, the backing layer being formed by casting, after casting the main body.
 16. The architectural panel of claim 1 further comprising a facing layer of lightweight concrete bonded to the second major face.
 17. An architectural panel of generally rectangular prismatic form comprising: a main body cast from lightweight concrete comprising one of aerated concrete and foamed concrete, and, as aggregate, one chosen from the group consisting of: sintered expanded clay, expanded polystyrene beads, pumice, expanded shale, bottom ash, ceramics; first and second major faces on the main body which are substantially planar and parallel to one another; first and second rectangular sheets or first and second wire reinforcing mesh sheets embedded in the main body and disposed substantially parallel to one another, next to the first and second major faces, respectively, wherein edges of each of the first and second wire reinforcing mesh sheet are disposed adjacent respective edges of the main body, and the first wire reinforcing mesh sheet includes an array of openings; and an array of recesses in the first major face, wherein each recess extends through a respective one of the openings in the first wire reinforcing mesh sheet and tapers inwardly from a relatively large mouth at the first major face to a relatively small base.
 18. The architectural panel of claim 17, further comprising a plurality of fixtures embedded in the main body to provide mounting points for the panel, each fixture comprising a plate fixed to a projecting bracket, wherein each plate is disposed adjacent the second major face, each bracket extends substantially perpendicular to the plate, an axial end of each bracket is disposed adjacent the first major face, each bracket includes an aperture extending through the axial end, with an internal screw thread in the aperture and the fixtures are fixed to the first and second wire reinforcing mesh sheets.
 19. The architectural panel of claim 18, further comprising a backing layer extending over the first major face and keyed into the recesses, the backing layer being formed by casting, after casting the main body.
 20. The architectural panel of claim 18 further comprising a facing layer of lightweight concrete bonded to the second major face. 